Method for forming products from a flue gas desulfurization by-product and products formed thereby

ABSTRACT

Compositions and methods for producing a manufactured product, a method for making a liquid absorbent, and processes for disposal of flammable liquids with a flue gas desulfurization by-product. The compositions for the manufactured products combine a binder and the by-product. The composition contains a greater percentage by weight of the by-product than the binder. The methods for producing manufactured products include dewatering the gypsum-depleted waste stream to reduce a water content, and forming the manufactured product. The method for making a liquid absorbent includes dewatering, granulating, drying, heating, and packaging a granulated gypsum-depleted composition as the liquid absorbent. The processes for disposal of flammable liquids include distributing a by-product into contact with flammable liquid, absorbing the liquid, transporting, and igniting the flammable liquid. The artificial soils are a combination of by-product and animal waste.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/941,163, filed May 31, 2007, which is hereby incorporated byreference herein in its entirety.

FIELD OF THE INVENTION

This invention relates to products, including flame retardant products,and methods for forming products from flue gas desulfurization waste.

BACKGROUND OF THE INVENTION

One of the many emissions from fossil fuel power generation is sulfurdioxide. The sulfur in the sulfur dioxide originates as an impurity inmany fossil fuels, particularly coal. Sulfur dioxide is a combustionproduct formed by reacting sulfur in the fuel with oxygen. Currentenvironmental regulations require industry to reduce emissions of sulfurdioxide because it is a source of acid rain. Accordingly, the powergeneration industry has adopted technologies to “scrub” the sulfurdioxide from effluent combustion gases. These technologies are referredto as flue gas desulfurization (FGD) technologies. In brief, FGDtechnology is used to at least partially remove sulfur dioxide fromcombustion gas in a coal burning power plant by injecting a slurrycomprising water and a lime or limestone material into a combustion gasexhaust stream. The lime or limestone reacts with the sulfur dioxide toproduce solids comprising compounds containing calcium and sulfur.Subsequent reaction of these compounds with oxygen produces calciumsulfate or gypsum and residual waste materials. Often gypsum is removedand sold while leaving a waste stream that is usually landfilled.

For example, in a wet scrubbing FGD process, the limestone is pulverizedand is added to water to form a slurry. The slurry is injected into anabsorber through which the combustion gas exhaust stream flows. Thelimestone in the slurry reacts with the sulfur dioxide in the combustiongas forming a compound containing calcium and sulfur. Once the slurrypasses through the absorber, the slurry returns to a water treatmentprocess.

The water treatment process has many purposes. One purpose is to oxidizeany calcium sulfite to calcium sulfate. Compressed air and sulfuric acidare added to the slurry at temperatures of between about 130° F. andabout 150° F. to oxidize any calcium sulfite present. The calciumsulfate is removed from the water by filtering, such as withhydrocyclones and dewatering belts. The water is further treated, asdescribed below, for reuse. The calcium sulfate, in a hydrated formknown as gypsum, may be sold to drywall manufacturers.

Besides the gypsum, the FGD process produces a waste stream comprisingfine, unsettled particles. Additional treatment of the water followingremoval of gypsum is required to remove the fine, unsettled particles. Asecondary water treatment process includes addition of various polymers,which facilitate flocculation and settling of the particles. The fine,unsettled particles and polymers are then pumped into a settling tank orclarifier where the particles flocculate and then settle due to gravity.Other additives may include biocides to control the bacteria content.Once the flocculated particles settle, they are pumped through anadditional dewatering step. After dewatering, the settled particlesappear as an orange, paste-like sludge. Gypsum, by contrast, is a purewhite material. The sludge is often referred to as OFS (orange fluffystuff). The OFS is a waste product, or by-product, of the FGD processfollowing removal of commercially pure gypsum. Typically, the OFS islandfilled.

The demand for electrical power is increasing. As the consumption ofcoal increases, the volume of the FGD waste stream (i.e. OFS) alsoincreases. What are needed are methods and products for turning OFS intoviable products.

SUMMARY OF THE INVENTION

According to one embodiment of the present invention, in one embodiment,a composition for producing a manufactured product is provided. Thecomposition comprises a binder and a by-product from a flue gasdesulfurization process combined with the binder. The by-product iscomposed of gypsum, a silicon-containing compound, and amagnesium-containing compound, wherein the composition contains agreater percentage by weight of the by-product than the binder. In oneembodiment, the binder is composed of a clay and the manufacturedproduct is drywall joint compound. In another embodiment, the binder iscomposed of a hydraulic cement, and the manufactured product is a brick,a brick veneer, or manufactured stone. In another embodiment, the binderis composed of a hydraulic cement, and the manufactured product is asheet of drywall.

In accordance with another embodiment of the invention, a method ofmaking a manufactured product using a waste stream from a flue gasdesulfurization process is provided. The waste stream has been depletedof gypsum so that the waste stream is enriched in a by-product. Themethod comprises dewatering the gypsum-depleted waste stream to reduce awater content thereof, and forming the manufactured product using theby-product contained in the dewatered, gypsum-depleted waste stream.

According to another embodiment of the invention, a method for making aliquid absorbent from a waste stream of a flue gas desulfurizationprocess follows removing a majority of gypsum from the waste stream. Inone embodiment, the method comprises dewatering the waste stream to forma gypsum-depleted composition containing a by-product, granulating thegypsum-depleted composition, drying the granulated gypsum-depletedcomposition at a first temperature, heating the granulatedgypsum-depleted composition to a second temperature hotter than thefirst temperature to react constituents of the granulatedgypsum-depleted composition, and packaging the reacted, granulatedgypsum-depleted composition as the liquid absorbent.

In yet another embodiment, a process for disposal of a flammable liquidis provided. The process comprises distributing a by-product from a fluegas desulfurization waste stream into contact with the flammable liquid,absorbing the contacted flammable liquid with the by-product,transporting the by-product and the absorbed flammable liquid to acontrolled environment, and igniting the flammable liquid tosubstantially remove the flammable liquid from the by-product ascombustion products.

In yet embodiment, an artificial soil is provided. The artificial soilcomprises a by-product from a flue gas desulfurization process, theby-product composed of gypsum, a silicon-containing compound, and amagnesium-containing compound; and animal waste combined with theby-product.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with a general description of the invention given above, andthe detailed description of the embodiments given below, serve toexplain the principles of the invention.

FIG. 1 is an schematic representation of a flue gas desulfurizationprocess;

FIG. 2 is an x-ray diffraction pattern of one sample of agypsum-depleted by-product from a flue gas desulfurization process;

FIG. 3 is a perspective view of drywall joint compound according to oneembodiment of a manufactured product of the present invention;

FIG. 4 is a perspective view of a brick according one embodiment of themanufactured product of the present invention;

FIG. 5 is a perspective view of a brick veneer according one embodimentof the manufactured product of the present invention;

FIG. 6 is a perspective view of a manufactured stone according to oneembodiment of the manufactured product of the present invention;

FIG. 7 is a perspective view of a sheet of drywall according to oneembodiment of the manufactured product of the present invention:

FIG. 8 is a partial cross-sectional perspective view of a landfillhaving a landfill liner according to one embodiment of the manufacturedproduct of the present invention;

FIG. 9 is a perspective view of a liquid absorbent according to oneembodiment of the manufactured product of the present invention; and

FIG. 10 is a perspective view of artificial soil according to oneembodiment of the manufactured product of the present invention.

DETAILED DESCRIPTION

An example of a FGD process is illustrated in FIG. 1. One skilled in theart will recognize that other FGD processes will have similar wastestreams as that described herein. Therefore, the embodiments shown anddescribed herein are not limited to the FGD process depicted in FIG. 1.One skilled in the art will also observe that the FGD processillustrated is just one portion of a coal burning power plant or otherfossil fuel burning power generation facility.

As shown in FIG. 1, a liquid slurry containing a calcium-containingcompound is injected into an absorber 10. During normal operation, fluegas from, for example, burning coal to generate electricity also flowsthrough the absorber 10. The calcium-containing compounds react with amajority of the gaseous sulfur dioxide in the flue gas forming calciumsulfate/sulfite. The gaseous sulfur is, therefore, substantially removedfrom the flue gas, which subsequently passes from the absorber 10. Theused liquid slurry is then directed to an oxidizer tank 12 where anysulfites are oxidized to sulfates most likely by addition of compressedair and sulfuric acid. The oxidized, used liquid slurry is then passedthrough a hydrocyclone 14 to separate the majority of the solids fromthe liquid. In this case, the solids are directed to another dewateringdevice 16 (vista belts). Between the two dewatering steps, gypsum isremoved from the used liquid slurry. The gypsum-depleted, used liquidslurry then passes to a clarifier 18 where a by-product is allowed tosettle. Various additives may be added to facilitate settling thereof.Following settling, another hydrocyclone 20, and possibly anotherdewatering device 22, separates the by-product 24 from the liquid.

FIG. 2 illustrates an example of an x-ray diffraction pattern of a driedsample of the by-product 24 of FIG. 1. The dried sample of theby-product was analyzed using a PANalytical X'pert Pro diffractometerusing copper x-rays. As shown in FIG. 2, the x-ray diffraction patterndepicts that the dried by-product is composed of major constituents ofgypsum (CaSO₄.2H₂O); a silicon-containing compound, in this case quartz(SiO₂); and a magnesium-containing compound, in this case brucite(Mg(OH)₂). While FIG. 2 depicts the by-product as composed of gypsum,quartz, and brucite, other silicon-containing and magnesium-containingcompounds may be observed depending on the conditions at the powergeneration facility, as set out below.

TABLE 1A lists an equivalent oxide analysis of the constituents of arepresentative sample of the by-product. The equivalent oxide analysiswas determined with atomic absorption analysis as is known in the art.By comparison, TABLE 1B lists the equivalent oxide constituents forrepresentative FGD gypsum sold to dry-wall manufactures.

TABLE 1A PRIMARY COMPOSITION (%) Loss on Ignition LOI 12 Sulfate, SO₃ 39Calcium, CaO 25 Silicon, SiO₂ 8 Magnesium, MgO 11 Aluminum, A1₂O₃ 2Choride, C1— 1 Iron, Fe₂O₃ 1 Fluoride, F— 1

TABLE 1B PRIMARY COMPOSITION (%) Sulfate, SO₃ 53 Calcium, CaO 39 Loss onIgnition LOI 7 Silicon, SiO₂ 1

One skilled in the art will observe that the composition and relativeproportions of the major constituents of the by-product may depend onthe source of the limestone, or lime, used in the FGD process; theimpurities in the coal; and other impurities and additives from thepower generation and the water treatment processes. Some variability inthe relative proportions of the constituents is, therefore, expected. Asevidenced by FIG. 2, the by-product is substantially free of calciumsulfite, however, calcium sulfate, silica, and brucite as well as othercalcium-containing compounds (e.g., CaF₂ and Ca₄Fe₂O₆(SO₃).12H₂O) existin detectable quantities. Based on the x-ray diffraction pattern and thefollowing tables, in one embodiment, the dried by-product comprises lessthan about 75 wt. % gypsum, and, in another embodiment, the driedby-product comprises less than about 50 wt. % gypsum. In contrast,gypsum used in commercial applications is more than 96 wt. % pure.

Also, the by-product is composed of particles generally having diametersof less than 50 microns. In particular, d₉₀ of less than 40 microns withd₅₀ of between about 3 to about 7 microns and d₁₀ of about 3 microns orless. The d₉₀, d₅₀, and d₁₀, represent particle size diameters belowwhich 90%, 50%, and 10% of the cumulative particle size distributionoccurs, respectively.

The embodiments of the present invention result from the discovery thatthe by-product has unexpected properties. In addition, applicant hasrealized that the by-product is readily mixable or combinable with othermaterials and that the mixtures may be made into products. One advantageof using the by-product is that the cost of the manufactured product isreduced. Another advantage is that the by-product enhances theproperties of the manufactured product beyond what one skilled in theart would predict. For example, as discussed below, manufacturedproducts composed of the by-product have an unexpected resistance toflame compared to gypsum products.

According to one embodiment of the present invention, a composition forproducing a manufactured product comprises a binder combined with agreater percentage by weight of the by-product. That is, the mixture isat least 50 wt. % by-product and balance binder. In another embodiment,the mixture is at least 80 wt. % by-product and balance binder.Additional water may be added depending upon the application. Forexample, an additional amount of water (about 10 wt. %) is added to themixture to make a slurry. In other embodiments, additional water may notbe required for subsequent processing.

In one embodiment, the binder is a clay, such as bentonite,montmorillonite, or natural or synthetic aluminosilicate. The by-productmay be mixed with the clay to form a plastic, clay-like body. Theclay-like body may be formed into products with techniques known in theart of clay forming, such as extrusion, jiggering, and casting.Therefore, these mixtures may be used to make any products normally madewith clay, such as bricks.

With reference to FIG. 3, the clay mixture may be packaged for directconsumer use rather than for making products. For example, a mixture ofthe clay binder, the by-product, and water has properties similar towall repair compounds such as joint compound 42. The joint compound 42is used to fill seams or joints defined between the abutting edges ofadjacent wallboard panels, such as gypsum drywall or wallboard panels,used to construct the interior walls of residential and commercialbuildings. The joint compound 42 may include additional additives, suchas thickeners and other agents apparent to a person having ordinaryskill in the art.

As shown in FIG. 3, the joint compound 42 may, therefore, be packaged byplacing it in a container, like a bucket 30, for direct commercial saleto a consumer and subsequent use by the consumer. The joint compound 42is applied from the bucket 30 directly to the wallboard joints using atrowel or the like. A fiberglass, cloth, or paper reinforcing tapematerial may be embedded within the wet joint compound 42. After thejoint compound 42 hardens, a second layer of the joint compound 42 isapplied over the joint and reinforcing tape to completely fill the jointand to more fully conceal the joint to create a smooth seamless wallsurface. After the second layer of the joint compound 42 hardens, thejoint compound 42 may be sanded smooth to reduce surface irregularities.Paint or a wall covering, such as wall paper, can then be conventionallyapplied over the joint compound 42 so that the joint and the drywallcompound are imperceptible under the paint or wall covering.

Alternatively, the joint compound 42 may also be used as a spacklingcompound and the like to repair other types of imperfections in walls soas to impart a continuously smooth appearance to the wall surface. Forexample, the joint compound 42 may be used to conceal defects caused bythe nails or screws used to affix the wallboard panels to the studs.

In one exemplary embodiment and as illustrated in FIG. 4, the binder isa bentonite, or another type of processed clay, and the manufacturedproduct is a landfill liner 32. In a representative embodiment, thebinder may be sodium bentonite, which a naturally occurring compound ina silicate clay formed from volcanic ash.

A solid waste landfill 34 is depicted in FIG. 4. The landfill 34, as isknown in the art, is constructed to prevent permeation of liquids fromlandfill waste material 36 into the water table 37 by capturing anyliquid passing through drainage layers 38, 40 with the liner 32 anddraining the captured liquid from the landfill 34 through the drainagepipes 26. To that end, in the prior art, the landfill 34 is constructedwith a liner of compacted clay and a plastic liner.

According to one embodiment of the manufactured product, a mixture ofthe by-product with sodium bentonite in the range of about 4 wt. % toabout 20 wt. % sodium bentonite (about 1 lb. (about 0.45 kilogram) ofby-product to about 0.25 lb. (about 0.11 kilogram) bentonite) is pliableand substantially impermeable. The mixture, however, may contain as muchas about 50 wt. % sodium bentonite depending on the desired cost of thelandfill liner 32. In any case, the liner 32 composed of the by-productand the sodium bentonite may replace the compacted clay liner of theprior art. The mixture may perform as well as, or better than, thecommercially available liners by substantially preventing liquidpermeation through the liner 32. The liner 32, however, may cost afraction of the cost of conventional liners, such as high densitypolyurethane (HDPE) sheeting.

In addition, the liner 32 may provide equivalent liquid permeability atreduced thicknesses. For example, standard liner thicknesses are atleast 36 inches (91 centimeters) of compacted clay. The mixture ofby-product and bentonite layered to a thickness of about 6 to about 12inches (about 15 to about 30 centimeters) may have similar liquidpermeability or hydraulic conductivity as a conventional landfill linercomposition that is 36 inches (91 centimeters) thick. Additionalapplications may include forming liners for farm ponds and the like.Alternatively, the liner 32 may be a composite structure that includes alayer of the mixture of the by-product and sodium bentonite clad betweensheets, or similar substrates, such as geotextiles.

In yet another embodiment, the by-product may be combined with othertypes of binders like any one of various types of hydraulic cements, forexample Portland cement. For example, a mixture composed of Portlandcement and by-product may be made into a variety of manufacturedproducts depending on the process used, as will be described below.

With reference to FIGS. 5, 6, 7, and 8, by way of examples only and notlimitation, the manufactured products may include brick 44 or block,brick veneer 46, stepping or manufactured stone 48, and a sheet of drywall 50, respectively, and other structural elements apparent to aperson having ordinary skill in the art. The construction of brick 44,brick veneer 46, manufactured stone 48, and dry wall sheets or wallboardpanels 50 are known to a person having ordinary skill in the art, aswell as the processed for making these and other types of manufacturedproducts. The mixture of Portland cement and by-product may also begunned onto support structures for improved fire resistance (not shown).Bricks 44, brick veneer 46, and manufactured stone 48 are commonlyinstalled on houses, commercial buildings, and other structures toprovide environmental protection, structural support, and attractiveexterior surfaces. Wallboard panels 50 are used to construct theinterior walls of residential and commercial buildings. The wallboardpanels 50 are attached to the building studs using nails or otherconventional fasteners.

Optionally, additional constituents may be added to the mixture ofhydraulic cement and the by-product used to make the bricks 44, brickveneer 46, and manufactured stone 48. These additional constituents mayinclude, for example, glass fiber reinforcement, gypsum, and flyashand/or bottom ash from a coal burning power plant. The presence of theseadditional constituents may improve the mechanical properties of themanufactured product.

As briefly described above, the by-product may exhibit exceptionalresistance to fire. The abovementioned manufactured products containingthe by-product are damage resistant when exposed to an open flame. Thatis, the manufactured product and the by-product itself does notdiscolor, spall, flake, or deform in any discernible manner, whenexposed to open flame at temperatures in excess of 1832° F. (1000° C.).In addition, once removed from the flames, the manufactured product orthe by-product alone is unexpectedly touchable without injury orsensation of pain. Hence, the manufactured product has a low thermalconductivity.

Furthermore, in another embodiment and with reference to FIG. 9,agglomerates 52 of the by-product will absorb and retain a large volumeof liquid 54. Because the products composed of the by-product are fireresistant, agglomerates 52 or other bulk products consisting essentiallyof dried by-product are uniquely suited for use as a liquid absorbent52, particularly for absorbing flammable liquids 54 such as hydrocarbonslike fuels, oils, solvents, thinners, etc.

For example, dry agglomerate of the by-product will increase in weightby about 50% by absorbing gasoline or diesel fuel oil. After absorbing aflammable liquid 54, the flammable liquid 54 contained within theby-product may be disposed of by igniting the flammable liquid 54. Theby-product remains unchanged and may be recovered and reused to absorbanother amount of flammable liquid. Therefore, the liquid absorbent 52may be used to absorb accidental fuel spills. The liquid absorbent 52holds the flammable liquid and will not release any significant amountinto the surrounding environment. The absorbent/fuel mixture may then betransported to a safe location, where the fuel may be ignited orotherwise disposed of in a safe manner.

According to another embodiment of the present invention, an artificialsoil 56 comprises a combination of the by-product and animal waste orexcrement, as shown in FIG. 10, such as feces, urine, and otherbio-solids. The artificial soil 56 may be distributed in a locationwhere there is a lack of topsoil, such as un-remediated strip mines andalong roadways. Furthermore, grass has been observed to growexceptionally well in the artificial soil 56. In one particularembodiment, the animal waste and the by-product are present in aboutvolumetrically equal amounts. In yet another embodiment, the artificialsoil 56 further comprises about 10 vol. % hydrated lime to reduceoffensive odors. As an alternative to the lime addition, the artificialsoil 56 may be thermally treated or composted. Additional additives,such as fertilizers, may be added to the content of the artificial soil56.

According to yet another embodiment of the present invention, a methodof making manufactured products comprises dewatering of thegypsum-depleted by-product and forming the manufactured product usingthe dewatered by-product. By way of example, a centrifuge and/or a pugmill may be used to reduce the water content of the by-product.Following dewatering, the by-product is less than about 50 wt. % water,and may be preferably less than about 30 wt. % water depending on theby-product content and the device used for dewatering. While less wateris preferable for transportation and handling purposes, some waterprevents dusting and may facilitate mixing the by-product with othermaterials.

In one specific embodiment, forming comprises mixing the by-product witha binder and fabricating the manufactured product from the mixture. Anyone of the binders set forth above may be mixed with the by-product.Furthermore, forming the manufactured product may include pressing theby-product. For example, a mixture of Portland cement and the by-productmay be formed into products by pressing. The mixture may be pressed intoa mold (not shown) with a cavity shaped to reflect a shape of themanufactured product. By way of example, the manufactured productsinclude the brick 44, brick veneer 46, manufactured stone 48, or drywallsheet 50. Pressing may be facilitated with a hydraulic press or otherforming techniques known in the art. In one embodiment, the mixture ispressed by hand into a block form. Once pressed, the resultingmanufactured product is allowed to set until hard and dry.

Alternatively, fabricating may include placing or pouring the dewateredby-product into a mold. The by-product sets and dries resulting in aproduct that substantially conforms to the mold. The poured productshave uses similar to commercially available bricks 44, blocks of allsizes, brick veneers 46, manufactured stone 48, and/or drywall sheet 50used in architectural, building, construction, and other structural andnon-structural applications. However, the material cost of the productsis less than the commercially available components. In addition, theproducts pressed from a mixture of the by-product may be lighter thancomparable commercially available products.

The method may further include heating the product to temperatures of atleast about 365° F. (185° C.). Following heating, the products, forexample, bricks, exhibit improved mechanical integrity. For example, theproducts formed from a mixture of Portland cement and by-product willreceive drywall screws without cracking such that when the screws areinserted with a cordless drill, the drill stalls before the drywallscrews strip out.

In another embodiment, a mixture of the dried by-product and Portlandcement may be heated to at least about 365° F. (about 190° C.) for about2 hours and bagged. Later use of the mixture may include pouring orpumping the dry mixture to a desired location. Once positioned, water isadded to the mixture. In one embodiment, between about 5 wt. % and 30wt. % water is added to the mixture. In another embodiment, a quantityof water is added to the mixture in excess of 30 wt. % withoutdegradation in properties. The water causes the mixture to harden.Mixing of the water with the mixture is not required. Thus, for example,the mixture may be distributed or pumped to a location, such as forindustrial grouting, for supporting machinery, and for shoring upequipment pads and other concrete structures. Once exposed to water themixture hardens but does not shrink. Other applications include thosesimilar to where hydraulic grouts and mortars are used. An aggregate,such as washed #57 stone (0.25 inch (0.64 centimeter) to 0.75 inch (1.9centimeters) diameter washed aggregate), may be mixed into the mixturefor additional structural strength. Generally, about 20 wt. % aggregateis added to the mixture. However, the weight percent aggregate may befrom about 5 wt. % to about 30 wt. %.

Similarly, a method for making a liquid absorbent 52 comprisesdewatering the by-product, granulating the dewatered by-product, anddrying the granulated by-product. Once dried, the granulated by-productis heated to a temperature of at least 365° F. to react theconstituents. Not wishing to be by theory, the reaction may include lossof chemically bound water and/or reaction between the constituentswithin the by-product. The reacted by-product is then packaged for useas a liquid absorbent 52.

In order to facilitate a more complete understanding of the invention,the following non-limiting examples are provided.

EXAMPLE 1

In this example, one five-gallon bucket of the by-product was mixed withabout 4 wt. % bentonite. In terms of weight, one five-gallon bucket ofthe by-product taken directly from a centrifuge (contains about 30 wt. %water) is about 55 lbs. (about 25 kg). Water was added to the mixture.The consistency was similar to that of drywall joint compound. Themixture was applied to a surface of a sheet of drywall and, afterdrying, the material sanded like a commercially available jointcompound.

EXAMPLE 2

In this example, one five-gallon bucket of the by-product (about 55 lbs.(about 25 kg)) was mixed with one five-gallon bucket of clay (about 55lbs. (about 25 kg)), in this case bentonite, in a cement mixer. About 5wt. % water was added to the mixture. The final mixture had plasticitysimilar to that of clay and may be suitable for use as a landfill liner.

EXAMPLE 3

In this example, one five-gallon bucket of gypsum was mixed onefive-gallon bucket of the by-product and with one-half of a five-gallonbucket of Portland cement together with a colorant. One-half of afive-gallon bucket of Portland cement weighs about 25 lbs. (about 11kg). Following mixing in the cement mixture, the mixture was poured intoa block form. A similar mixture, but one having less water was pressedinto a block. In either the pressed or poured case, a decorative stoneveneer was produced having equivalent aesthetic characteristics ascommercially available stone veneer. A garden stepping stone was alsoproduced.

EXAMPLE 4

In this example, one five-gallon bucket of the by-product was mixed withone-half of a five-gallon bucket of Portland cement. One 20 ounce (570gm.) cup full of glass fiber reinforcement was added to that mixture. Inaddition, 20 ounces (570 gm.) of commercially available concrete dye wasadded to the mixture. After mixing in the cement mixer, the mixture wasdumped into a decorative stone veneer mold and pressed by hand. Thewater content was increased and the mixture was poured into a mold. Ineither case, a decorative stone veneer was produced having equivalentaesthetic and functional characteristics as commercially available stoneveneer.

TABLE 2 lists the equivalent oxide constituents of the decorative stonedetermined by atomic absorption spectroscopy.

TABLE 2 PRIMARY COMPOSITION (%) Calcium, CaO 47 Sulfate, SO₃ 32 Loss onIgnition LOI 9 Silicon, SiO₂ 7 Iron, Fe₂O₃ 2 Magnesium, MgO 1 Aluminum,A1₂O₃ 1 Potassium, K₂O 1

EXAMPLE 5

In this example, one five-gallon bucket of the by-product (about 55 lbs.(about 25 kg).) was mixed in a cement mixer with one-half of afive-gallon bucket of Portland cement (about 25 lbs. (about 11 kg)) anda 20 ounce (570 gm.) cup full of glass fiber reinforcement. Theresulting mixture was pressed into a block and allowed to dry andharden. The final block dimensions were 8⅝ inches (20 centimeters) by 4⅛inches (20 centimeters) by 3⅞ inches (20 centimeters). The block weighedabout three pounds. By comparison, a commercially available cement blockmeasuring 7⅝ inches (20 centimeters) by 3⅝ inches (20 centimeters) by 2¼inches (10 centimeters) and weighs about four pounds.

TABLE 3 lists the equivalent oxide constituents of the block determinedby atomic absorption spectroscopy.

TABLE 3 PRIMARY COMPOSITION (%) Calcium, CaO 43 Silicon, SiO₂ 15 Loss onIgnition LOI 13 Sulfate, SO₃ 9 Iron, Fe₂O₃ 9 Magnesium, MgO 4 Carbonate3 Aluminum, A1₂O₃ 3 Potassium, K₂O 1

EXAMPLE 6

In this example, the block of Example 5 was heated to about 365° F. andheld at that temperature for about two hours. The final weight of theblock was two pounds. To demonstrate the fire resistance of thematerial, a propane torch was positioned such that the flame impinged onthe surface of the block for about two minutes. The block turned orangeat the point of flame impingement. The block did not crack or spall.Following the removal of the propane torch, the surface of the block wasimmediately (less than about 10 seconds) cool enough to touch withoutinjury or pain.

EXAMPLE 7

In this example, one five-gallon bucket of the by-product was mixed in acement mixer with one-half of a five-gallon bucket of Portland cementand a 20 ounce (570 gm.) cup full of glass fiber reinforcement. Theresulting mixture was formed into a sheet similar to a sheet of drywalland allowed to dry and harden. The sheet was about 4 feet (about 1.2meters) by 8 feet (2.4 meters) by ⅝ inch (20 centimeters) thick. Thesheet of the mixture was attached, like a sheet of drywall, to woodentwo-by-fours. A flame from a propane torch was directed onto the sheet.As with the previous examples, the manufactured product did not appearto deteriorate due to the heat or from contact with the flames from thetorch. Applicant also noted that the two by fours showed no sign ofbeing burnt.

EXAMPLE 8

In this example, one five-gallon bucket of gypsum was mixed withone-half of a five-gallon bucket of kiln-dried by-product (at about 365°F. (about 190° C.) for between about 1 and 2 hours) and that mixture wasmixed with one five-gallon bucket of Portland cement. The one-half of afive-gallon bucket of kiln-dried by-product weighed about 13.75 lbs(about 6.25 kg). The mixture was poured into a series of 20 ounce (570gm.) plastic cups. Water was added to the cups without mixing. Followinga five to ten minute period of time, the mixture had hardened. Onceexposed to water the mixture hardens but does not shrink. Applicationsinclude those that are similar to application for hydraulic grouts andmortars. An aggregate, such as washed #57 stone (0.25 inch (0.64centimeter) to 0.75 inch (1.9 centimeters) washed aggregate) of about 10wt. %, may be mixed into the mixture for additional structural strength.

EXAMPLE 9

In this example, one five-gallon bucket of by-product, one five-gallonbucket of flyash, one-half of a five-gallon bucket of Portland cement,and one 20 ounce (570 gm.) cup of concrete fiber mesh were mixed in thecement mixer. Applications for this mixture include any number ofstructural products including, but not limited to, sheet, block, brick,synthetic stone, and sheets of drywall. Other applications include thosewhich require some fire protection. The mixture and bulk products of themixture were heated to at least 365° F. (190° C.). Both the heat treatedparts and unheated mixtures exhibit exceptional fire resistance asdescribed in Example 6 above. Therefore, applications, which by code orregulation require some fire resistance, such as coating structuralsteel, may benefit from the fire resistance that the mixture exhibits.The mixtures include formed components which, when assembled, enclosesteel girders and posts. Alternatively, the mixture may be gunnedsimilar to a commercially available gunning mixture onto the steelgirder or surface of a steel post.

TABLE 4 lists the equivalent oxide constituents of the mixture asdetermined by atomic absorption spectroscopy.

TABLE 4 PRIMARY COMPOSITION (%) Calcium, CaO 38 Sulfate, SO₃ 27 Silicon,SiO₂ 14 Loss on Ignition LOI 7 Iron, Fe₂O₃ 7 Aluminum, A1₂O₃ 5Magnesium, MgO 1 Potassium, K₂O 1

EXAMPLE 10

In this example, one five-gallon bucket of the by-product, one half of afive-gallon bucket of Portland cement, and one five-gallon bucket ofbottom ash were mixed in the cement mixer. About 20 ounces (about 570gm.) of fiber was added to the mixture. A variety of structural productsincluding bricks, blocks, stone veneer, and stepping stone were pressedor poured from the mixture. Each component exhibited fire resistance, asdescribed in Example 6 above.

TABLE 5 lists the equivalent oxide constituents of the mixturedetermined by atomic absorption spectroscopy.

TABLE 5 PRIMARY COMPOSITION (%) Calcium, CaO 37 Silicon, SiO₂ 18Sulfate, SO₃ 15 Iron, Fe₂O₃ 11 Loss on Ignition LOI 8 Magnesium, MgO 5Aluminum, A1₂O₃ 5 Potassium, K₂O 1

EXAMPLE 11

In this example, one five-gallon bucket of the by-product, one-half of afive-gallon bucket of Portland cement, and two, 20 ounce (570 gm.) cupsof concrete fiber mesh were mixed in the cement mixer. Similar to theabove examples, this mixture was formed into a variety of structuralproducts. In addition, the mixture may be gunned or pumped onto otherproducts or formed into products, as described above.

TABLE 6 lists the equivalent oxide constituents of the mixturedetermined by atomic absorption spectroscopy.

TABLE 6 PRIMARY COMPOSITION (%) Calcium, CaO 42 Sulfate, SO₃ 15 Silicon,SiO₂ 14 Loss on Ignition LOI 12 Magnesium, MgO 5 Iron, Fe₂O₃ 5Carbonate, CO₂ 3 Aluminum, A1₂O₃ 3 Potassium, K₂O 1

EXAMPLE 13

In another example, the by-product was initially in a bulk unformedstate, such as a shovel full of material. While in that form, theby-product was heated to about 365° F. (about 190° C.) for about 2hours. After cooling, the heat-treated by-product was placed ingasoline. The bulk by-product absorbed at least 50% of its weight ingasoline in about 10 minutes. While submerged, the by-product releasedbubbles. It appears that when the bubbles cease, the by-product isnearly at full of liquid. The by-product with absorbed gasoline was seton fire and burned for nearly an hour. The surface temperature of theby-product exceeded 750° F. (400° C.) (the maximum temperaturerecordable by the noncontact pyrometer). When the fuel was depleted andflames extinguished, the surface temperature 30 seconds after the burnended was 170° F. (77° C.). After about 4 minutes the temperature was140° F. (60° C.). The by-product appeared unaffected by the exposure toeither the fuel or to the elevated temperatures. In one example,repetitive use of one chunk of bulk by-product turned its exteriorsurface black. The blacken surface was easily removed. By comparison,bulk heat-treated gypsum does not absorb gasoline.

Similarly, a brick formed from the by-product, but not heat treated, andweighing about 3 pounds (about 1.4 kg) was used to absorb 1 pound (0.45kilogram) of diesel fuel oil in about 25 minutes. When the diesel fueloil was ignited, the surface temperature of the brick exceeded 750° F.(400° C.) while the diesel fuel oil burned. The surface temperatureimmediately after the flames were extinguished was about 180° F. (about82° C.) and dropped to about 160° F. (about 71° C.) after about 4minutes.

EXAMPLE 14

In another example, one five-gallon bucket of the by-product was mixedwith one five-gallon bucket of human waste in a cement mixer to formartificial soil. The mixture was about 50/50 by volume. The resultingmixture was poured into a 13 inch (33 centimeters) by 24 inch (61centimeters) wooden tray to a depth of about 6 inches (about 15centimeters). Grass seed was distributed across the top of theartificial soil. The grass seed was a “Kentucky 31” mixture of bluegrass, fescue, clover, and other seed. In normal environmentalconditions, the grass seed germinated in about 2 days and was mowablewithin a week, thus representing a growth rate of about 5 to 6 inches(about 13 to 15 centimeters) per week. Potential applications includetopsoil replacement in areas that lack sufficient soil quantity orquality of soil, such as around new construction.

TABLE 6 lists the equivalent oxide constituents of the artificial soildetermined by atomic absorption spectroscopy.

TABLE 6 PRIMARY COMPOSITION (%) Loss on Ignition LOI 27 Sulfate, SO₃ 27Calcium, CaO 17 Silicon, SiO₂ 13 Magnesium, MgO 9 Aluminum, A1₂O₃ 4Phosphate, P₂O₅ 1 Choride, C1— 1 Iron, Fe₂O₃ 1

EXAMPLE 15

In another example, a mixture of the by-product and animal waste, butwith about 25% hydrated lime, also referred to as slaked lime, was mixedin a cement mixer. The hydrated lime is common additive used to controloffensive odors. One five-gallon bucket of the by-product, onefive-gallon bucket of human waste, and one-quarter of a five-gallonbucket of hydrated lime were introduced to the cement mixer. Followingthorough mixing, the mixture was dumped into a wooden tray havingdimension of about 13 inches (about 33 centimeters) by about 24 inches(about 61 centimeters). The artificial soil depth was again about 6inches (about 15 centimeters) deep. Kentucky 31 grass seed wasdistributed over the surface of the soil. In normal environmentalconditions, the grass seed germinated in about 2 days and was mowablewithin a week, thus representing a growth rate of about 5 to 6 inches(about 13 to 15 centimeters) per week.

TABLE 7 lists the equivalent oxide constituents of the artificial soilwith hydrated lime determined by atomic absorption spectroscopy.

TABLE 7 PRIMARY COMPOSITION (%) Loss on Ignition LOI 27 Sulfate, SO₃ 25Calcium, CaO 22 Silicon, SiO₂ 11 Magnesium, MgO 9 Aluminum, A1₂O₃ 3Phosphate, P₂O₅ 1 Choride, C1— 1 Iron, Fe₂O₃ 1

EXAMPLE 16

In this example, one five-gallon bucket of gypsum was mixed with onefive-gallon bucket of the by-product and one five-gallon bucket of driedhuman waste. The consistency appeared to be similar to that of moistdirt. The mixture was compressible, yet had a granular appearancefollowing mixing. No hydrated lime was added though the mixture did nothave an odor. This mixture may also be used as artificial topsoil withsimilar results as those illustrated in Examples 14 and 15.

In another embodiment, a composition for a manufactured componentconsists essentially of a by-product from a flue gas desulfurizationprocess and a binder. As used herein, “consisting essentially of” meansthat no other elements are intentionally added to the mixture. However,the impurity content of other elements from the waste stream or thefabrication process may be contemplated.

While the present invention has been illustrated by the description ofone or more embodiments thereof, and while the embodiments have beendescribed in considerable detail, they are not intended to restrict orin any way limit the scope of the appended claims to such detail.Additional advantages, products and applications will readily appear tothose skilled in the art. The invention is therefore not limited to thespecific details, representative method and illustrative examples shownand described. Accordingly, departures may be made from such detailswithout departing from the scope of the general inventive concept.

1. A composition for producing a manufactured product, the compositioncomprising: a binder; and a gypsum-depleted by-product from a flue gasdesulfurization process that produces gypsum separately from thegypsum-depleted by-product, combined with the binder, thegypsum-depleted by-product composed of less than about 75 wt. % gypsum,a silicon-containing compound, and magnesium-containing compound,wherein the composition contains a greater percentage by weight of thegypsum-depleted by-product than the binder.
 2. The composition of claim1 wherein the gypsum-depleted by-product includes less than about 50 wt.% gypsum.
 3. The composition of claim 1 wherein the binder is composedof a clay, and the manufactured product is drywall joint compound. 4.The composition of claim 1 wherein the binder is composed of a hydrauliccement, and the manufactured product is a brick, a brick veneer, ormanufactured stone.
 5. The composition of claim 1 wherein the binder iscomposed of a hydraulic cement, and the manufactured product is a sheetof drywall.
 6. The composition of claim 1 wherein the binder is composedof sodium bentonite, and the manufactured product is a landfill liner.7. The composition of claim 6 wherein the landfill liner is betweenabout 80 wt. % and about 96 wt. % of the by-product.
 8. An artificialsoil comprising: a gypsum-depleted by-product from a flue gasdesulfurization process that produces gypsum separately from thegypsum-depleted by-product, the by-product composed of gypsum, asilicon-containing compound, and a magnesium-containing compound; humanwaste combined with the gypsum-depleted by-product; and hydrated limecombined with the gypsum-depleted by-product and the human waste.
 9. Theartificial soil of claim 8 wherein the gypsum-depleted by-product andthe human waste are present in about volumetrically equal amounts. 10.The artificial soil of claim 8 wherein the hydrated lime composes about10 vol. % of the artificial soil.
 11. The artificial soil of claim 8wherein the gypsum-depleted by-product contains less than about 75 wt. %gypsum.
 12. The composition of claim 1 wherein the binder is composed ofPortland cement.